【摘要】 小模数齿轮加工过程中，滚齿切削时易于产生显著的热变形，进而影响其尺寸精度和服役性能.基于展成法加工原理和齿坯材料切除机制，提出小模数齿轮断续滚齿切削热力耦合计算模型.设计多级滚切速度下的钢制小模数齿轮试件试验，测算试件表面缺陷、粗糙度与公法线偏差.对比公法线偏差测量值和塑性应变仿真值，验证上述计算模型的正确性.研究齿轮模数、切削速度和传热条件对切削应力、表面温度及热变形的影响规律.结果表明：切削应力水平与模数负相关，与切削速度正相关；齿面缺陷密集度、表面温度和热变形均与切削速度正相关.适当降低滚刀转速、减小滚刀直径及强化切削区对流换热，可减小滚齿热变形，提高齿形精度和表面质量.更多还原

【Abstract】 In the fine-pitch gear manufacturing process, significant thermal deformation is prone to occur during the gear hobbing, which in turn affects its dimensional accuracy and operational performance. Based on the principle of spreading processing and the mechanism of metal destruction, a thermal-mechanical coupling model is proposed for the intermittent hobbing of fine-pitch gears. Steel fine-pitch gear specimens are prepared using various hobbing speeds. By comparing the measured profile deviations with the simulated plastic strain values, the accuracy of the proposed model is verified. The influence of modulus, cutting speed, and heat transfer condition on cutting stress, temperature, and thermal deformation is studied. The results show that the cutting stress is negatively correlated with the gear modulus and positively correlated with the cutting speed. The tooth surface defect density, temperature, and thermal deformation are positively correlated with the cutting speed. To reduce heat deformation and improve tooth accuracy and surface quality, the rotational speed of the hob and its diameter should be decreased.Additionally, convective heat transfer in the cutting zone should be enhanced.更多还原